Additive Manufacturing for Sustainable Electromagnetic Interference Shielding: Materials Discovery, Structural Optimization, and Machine Learning

Abstract

ABSTRACT The rapid expansion of wireless technologies has intensified the need for effective electromagnetic interference (EMI) shielding to ensure the reliability of electronic devices, while the increasing generation of electronic and plastic waste has created a demand for sustainable and environmentally friendly shielding materials. Additive manufacturing (AM) offers unprecedented freedom to design and fabricate highly tailored EMI shields, enabling precise control over structure, composition, and performance. This review highlights recent progress in the development of AM‐based EMI shields using recycled, bio‐based, and environmentally‐friendly materials. We explore how structural design and optimization strategies influence both electromagnetic wave attenuation and mechanical integrity, and discuss the emerging role of simulation and machine learning (ML) in performance prediction and design acceleration. Life cycle assessment (LCA) challenges are examined, along with sustainable manufacturing pathways to minimize environmental impact. We conclude with future perspectives, emphasizing the transformative potential of AM to advance next‐generation, high‐performance, and sustainable EMI shielding solutions.